Pallet system

ABSTRACT

A pallet system for use in the transportation and/or storage of elongate or extruded products which is mountable and demountable without the use of tools is disclosed. The pallet system including a plurality of base members, each having interlockable elements on at least one end and which are adapted to engage and interlock with a similarly configured adjacent base member such that an elongate base structure can be formed from the base members, and wherein each of the base members is also adapted to support a plurality of upright members.

CROSS-REFERENCES

This application is a cognated complete-after-provisional (CAP) claiming priority from provisional patents, NZ 561957 as filed on 26 Sep. 2007 and NZ 564290 as filed on 13 Dec. 2007.

FIELD OF THE INVENTION

This invention relates to a pallet system, and in particular, but not exclusively to a pallet system for use in the transportation and/or storage of extruded products.

BACKGROUND

Extruded products, such as aluminium or plastic extrusions, are typically long, and can be fragile or easily damaged. The transportation and storage of these extrusions presents unique difficulties. To be handled efficiently they are often strapped together in bundles, however even though the bundles may not be particularly heavy they can be difficult to handle due to their size and shape, and the relatively fragile nature of the extrusions.

When carefully bundled and supported however, the extrusions can be used support one another, and a well secured and protected bundle of extrusions can be handled without undue difficulty.

For this reason, it is common to construct purpose built pallets out of wood to match the length requirements of the particular extrusions, to hold the bundles in relatively neat stacks and ideally to facilitate secure stacking of one bundle on top of another. Ideally the pallets support the bundles of extrusions in such a manner that the bundles have a generally rectangular cross section, and have a flat top that is at least partially protected, to allow stacking of one bundle over another. The pallets can also provide access for fork lift tines to allow the pallets to be lifted or to be moved about using a forklift.

For these reasons, the pallet systems for extrusions are ideally three dimensional, providing structure and protection underneath the stack, structure and optionally some protection on the sides, and at least limited structure or protection over the top of the extrusions.

Pallet systems that are presently used are generally constructed from wood. However, due to the size requirements, and the three dimensional nature of the pallets, their construction is relatively expensive. In addition, relatively significant quantities of wood are used. The wood that is used to make the pallets is generally discarded after a single use since it is often not convenient to return long lengths of wood, which are often partly damaged, back to their origin.

The use of quantities of wood in this manner is increasingly being viewed as potentially harmful to the environment.

Object

It is therefore an object of the present invention to provide a pallet system and/or method which will at least go some way towards overcoming the above mentioned problems, or at least provide the public with a useful choice.

Statements of the Invention

Accordingly, in a first aspect, the invention may broadly be said to consist in a pallet system, having a plurality of base members, each base member being adapted to engage with another base member such that a generally elongate base structure can be formed from the base members, and the base members also being adapted to support a plurality of upright members.

Preferably each base member includes interlockable elements on at least one end adapted to interlock with similarly configured interlockable elements of an adjacent base member.

Preferably each base member includes the interlockable elements on both ends.

Preferably the interlockable elements include one or more fingers adapted to interlock with corresponding fingers or recesses of an adjacent base member.

Preferably the fingers have a generally “C” shaped cross section.

Preferably the interlockable elements are adapted to receive fasteners to further secure any joint between interlocked base members.

Optionally the interlockable elements of each base member adapted to snap lock with the corresponding interlockable elements of an adjacent base member.

Optionally each base member can be engaged with an adjacent base member using one or more joining members.

Preferably each joining member is adapted to engage with one or more first sockets or pins provided on each base member.

Preferably the or each joining member can be fitted to a top side of each base member.

Preferably the or each joining member fits into each base member with an interference fit or a snap fit.

Preferably the or each joining member can be fitted to each base member without the use of tools.

Preferably the joint between adjacent base members provides a recess or recesses adapted to accommodate or retain a packaging strap.

Preferably each base member includes one or more base sockets, or a part of one or more sockets, adapted to support an upright member.

Preferably at least some of the base sockets are situated at or adjacent each joint between adjacent base members.

Preferably the upright members can be engaged with the base members without the use of tools.

Preferably the pallet system also includes cap members which are adapted to engage with any upright members that are used.

Preferably the cap members have cap sockets which are adapted to engage with any upright members that are used.

Preferably the cap members have recesses or channels which can be used to accommodate or retain packaging strap material.

Preferably each base member has a generally rectangular or square shape when viewed from above.

Preferably the lower surface of each base member includes a region that is elevated with respect to at least one other region of the remainder of the lower surface.

Optionally each base member also includes one or more legs which extend below a body section of each base member.

In a second aspect, the invention may broadly be said to consist in a pallet load of extrusions incorporating at least one pallet system substantially as specified herein.

Preferably the pallet load of extrusions is held together using straps which are aligned with the joint between adjacent base members.

In a third aspect, the invention may broadly be said to consist in a method of palletising elongate or extruded products including the steps of;

-   -   engaging two or more pallet bases to form a generally elongate         pallet base,     -   engaging a plurality of upright members into sockets provided in         the pallet base,     -   loading the pallet with elongate or extruded products,     -   placing one or more top members over the elongate or extruded         products and engaging the top members with the upright members,         and     -   applying a packaging strap about the loaded pallet at least at         each location where a base member is joined to an adjacent base         member.

Preferably the method further includes the fitting of joining members to engage adjacent base members.

Preferably the joining members are fitted to the top of the base assembly.

The invention may also broadly be said to consist in the parts, elements and elements referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of the parts, elements or elements, and where specific integers are mentioned herein which have known equivalents, such equivalents are incorporated herein as if they were individually set forth.

DESCRIPTION

Further aspects of the present invention will become apparent from the following description which is given in the form of two examples only, and with reference to the accompanying drawings in which:

FIG. 1 is a perspective view of a first example of a pallet system,

FIG. 2 is a plan view of a base assembly of the first example of a pallet system,

FIG. 3 is a perspective view of a base member of the first example of a pallet system,

FIG. 4 is a side elevation view of a base member of the first example of a pallet system,

FIG. 5 is a perspective view of a joining member of the first example of a pallet system,

FIG. 6 is a perspective view of a side panel of the first example of a pallet system,

FIG. 7 is a perspective view of a cap member of the first example of a pallet system,

FIG. 8 is a perspective view of a base extension member of the first example of a pallet system,

FIG. 9 is a bottom plan view of a second example of a pallet system,

FIG. 10 is a side elevation view of a second example of a pallet system,

FIG. 11 is a perspective view of the second example of a pallet system,

FIG. 12 is a perspective view of a typical joint between adjacent base members of the second example of a pallet system,

FIG. 13 is an exploded perspective view of the joint shown in FIG. 12,

FIG. 14 is an upper perspective view of a capping member of the second example of a pallet system,

FIG. 15 is a bottom perspective view of the capping member of the second example of a pallet system,

FIG. 16 is amend elevation view of two loaded pallets stacked one on top of the other,

FIG. 17 is an enlarged view of a joint between the two stacked pallets,

FIG. 18 is an exploded partially cutaway perspective view of one of the stacked pallets, and

FIG. 19 is a partially cutaway perspective view of one of the stacked pallets.

FIRST EXAMPLE

With reference to FIGS. 1 to 5, a first example of a pallet system (10) according to the present invention is shown. FIG. 1 shows a base assembly structure (11) which includes a plurality of base members (13). The pallet system (10) can also include a number of upright members (15), side panels (17) and/or base extension members (19). The pallet system (10) is designed for use in the storage and transportation of elongate products, for example extrusions. It can be seen that the pallet system (10) is made up of a number of parts that can be assembled together to form the elongate base assembly structure (11) onto which a number of extrusions can be placed. The base assembly (11) can be strapped to the extrusions, to form a packaged set of extrusions in which the extrusions and the base assembly (11) act together to form a rigid and protected unit which can be handled using standard lifting and transportation equipment. The pallet system (10) is particularly useful for the storage and transportation of aluminium extrusions, for example extrusions that are four to six metres in length.

Each base member (13) is adapted to engage with another base member (13) to form the elongate base assembly (11). In this example, each base member (13) can be engaged with an adjacent base member (13) using one or more joining members (21) that are adapted to fit into first base sockets (23) provided on each base member (13). The base members (13) in this example have a generally rectangular or square shape when viewed from above, and each have a lattice frame construction and can be made from a plastics material.

While it is envisaged that the joining members (21) could take a number of forms, in this example each joining members (21) comprises a body section (25) with four pins (27) that all extend from one side of the body section (25). One pair of pins (27) can be fitted into a pair of adjacent first base sockets (23) in one base member (13) and the other pair of pins can be fitted into a pair, of adjacent base sockets (23) in another base member (13). In this way each joining member (21) can tie two adjacent base members (13) together. It can be seen that in this example, each base member (13) includes three pairs of base sockets (23) at each end, and therefore three joining members (21) can be used to make a secure connection between adjacent base members (13).

It can also be seen in the figures that the top surface of each of the sockets (23) is recessed below a top surface (29) of the base members (13). The amount that the sockets (23) are recessed below the top surface (29) is substantially the same as the thickness of the body section (25) of each joining member (21). This means that the top surface of each joining member can lie flush with the top surface (29) of the base members (13), and means that the top surface of the base assembly structure (11) provides a flat platform upon which a number of extrusions can be laid.

Preferably the pins (27) of each joining member (21) fit into each base member (13), or the sockets (23) of each base member (13), with an interference fit or a snap fit. However, since each joining member (21) can be fitted to the top side of each base member (13), and the top of the joining members (21) can be flush with the top surface (29) of each base members (13), a load of extrusions that lie on top of the base assembly structure (11) can also help to prevent the joining members (21) from migrating out of the sockets (23) to help prevent the base members (13) from becoming disconnected.

The construction, or disassembly, of the base assembly structure (11) can be carried out without any requirements for tools since the joining members (21) can be fitted to each base member, or be removed, by hand.

It can be seen in FIG. 4 that each base member (13) includes two legs (31) which hold a body portion (33) of each base member a small distance above the ground. The slight elevation provided by the legs (31) is enough to allow the tines of a forklift to get under the base assembly structure (11). It can also be seen that the lower outside corner of each leg (31) is provided with a step. The step (35) is configured such that when two adjacent base members (13) are joined together, the adjacent steps (35) form a recess or channel that runs along the length of the join. The recess provided by the joint between adjacent base members (13) can accommodate or retain a packaging strap, for example a plastic or a metal strap that is used to hold extrusions onto the base assembly structure (11).

The base assembly (11), or the base members (13), is/are adapted to support the upright members (15), and in this example each base member (13) includes a part of a second base socket (37) at each corner for this purpose. When two base members (13) are joined the adjacent parts of the second base socket (37) on each corner of the base members (13) join to form a single second base socket (37).

Each upright member (15) can simply be made of a length of wood, having a suitable cross section to fit into the second base sockets (37). The length of wood, or other material, can be cut to length to suit the height of a bundle of extrusions. Since the upright members (15) can be engaged with the base members (13) by inserting them into the second base sockets (37) there is no requirement to use tools to construct the pallet system (10).

The pallet system (10) can also include cap members (39)—refer to FIG. 7. The cap members (39) are adapted to engage with the upright members (15) that are used, and to sit over the top of a load of extrusions. In FIG. 1, upright members (15) are only shown fitted to one side of the base structure assembly (11), however, in use, upright members (15) would usually be fitted to both sides of the base structure assembly (11). It can be seen that on a lower side (41), and at each end, of each cap members (39), a cap socket (43) is provided. The cap sockets are similar in size to the second base sockets (37), and for this reason they are also adapted to engage with any upright members (15) that are used.

Preferably the cap members (39) also have recesses or channels (45) which can also be used to accommodate or retain any packaging strapping material. In this way, any packaging or strapping material that is used can be held securely in line with the joint between adjacent base members (13), and in line with the uprights (15) and the cap members (39), and can help to hold the whole assembly of the base structure (11) and any extrusions together in a relatively stable package that is suitable for handling, transportation and storage.

When one pallet-load of extrusions is stacked on another, the legs (31) of the upper load can rest on the cap member (39) of the lower load.

As mentioned above, the pallet system (10) can also include side panels (17). The side panels can be fitted to the base assembly (11) as shown in FIG. 1 and can provide additional protection to any goods that are stored or transported using the pallet system (10). FIG. 6 shows a side panel in more detail. Each side panel (17) is essentially a flat panel that includes attachment means so that it can be attached to the base assembly (11). In this example, the attachment means includes a first half hinge (47) feature that is part of each side panel (17), and which is adapted to mate with a second half hinge (49) feature that is part of each side of each base member (13).

And, also as mentioned above, the pallet system (10) can include base extension members (19)—see FIG. 8. FIGS. 1 and 2 show a base structure assembly (11) that includes one base extension member (19) at each end. The base extension members (19) are similar in 20, configuration to the base members (13) but have a shorter length. For example, while the base members can have a length in the range of 0.8 to 1.2 metres, the base extension members (19) may have a length in the range of 0.1 to 0.3 metres. Used in conjunction with a number of base members (13), the shorter base extension members (19) can allow the overall length of the base structure assembly (11) to more closely match the overall length of the goods that are to be loaded onto the pallet system (10). In addition, the use of a shorter base extension members (19) at each end of the base structure (11) provides second base sockets (37) that are nearer to the end of the base structure (11), and the opportunity to place upright members (15) and cap members (39) near the ends.

The pallet system (10) provides a method of palletising elongate or extruded products that includes the steps of;

-   -   engaging two or more pallet bases to form a generally elongate         pallet base,     -   engaging a plurality of upright members into sockets provided in         the pallet base,     -   loading the pallet with elongate or extruded products,     -   placing one or more top members over the elongate or extruded         products and engaging the top members with the upright members,         and     -   applying a packaging strap about the loaded pallet at least at         each location where a base member is joined to an adjacent base         member.

The method can further include the fitting of joining members to engage adjacent base members, and preferably the joining members are fitted to the top of the base assembly.

When a load of elongate or extruded goods has been transported using the pallet system (10), and the goods have been unloaded from the pallet, the parts can be disassembled, and the component parts can be returned for re-use.

SECOND EXAMPLE

With reference to FIGS. 9 to 19, a second example of a pallet system (60) according to the present invention is shown. FIGS. 9 and 10 show a base assembly structure (61) which includes a plurality of base members (63). As with the first example of a pallet system (10) described herein, the pallet system (60) can also include a number of upright members (64) and/or base extension members (65).

The second example of a pallet system (60) is similar to the first example of a pallet system (10) except as follows.

In this example, each base member (63) includes interlockable elements (67) that are adapted to interlock with similarly configured interlockable elements (67) of an adjacent base member (63). While each base member (63) can include interlockable elements (67) on just one end, for example to construct a base assembly structure (61) of just two base members (63), preferably each base member (63) includes the interlockable elements (67) on both ends. Clearly the base extension members (65) require interlockable elements (67) at just one end only.

It can be seen that the base members (63) can be injection molded plastic parts having longitudinal members (63 a), transverse members (63 b) and diagonal members (63 c) for improved rigidity. The base extension members (65) can be made by simply cutting a base member (63) laterally, between transverse members (63 b), at a wide range of desired locations along its length. In this way a base assembly structure (61) of a wide range of overall lengths can be formed, as the length of the base extension members (65) can be chosen at will.

It is envisaged that the interlockable elements (67) could take a number of forms, however in this example, the interlockable elements (67) include one or more fingers (69) that are adapted to interlock with corresponding fingers or recesses of an adjacent base member (63).

It can be seen in the figures that in this example the fingers (69) each have a generally “C” shaped cross section. Each base member (63) has two short fingers (71) and two long fingers (73) on each end. The long fingers (71) are sized and shaped to fit about the short fingers (71) of an adjacent base member (63), and each pair of intertwined long and short fingers (71) and (73) can be further fastened together using a suitable fastener, for example a screw (75). In this example, a boss (76) is provided on the inside of each of the short fingers (71) to accommodate the threads of the screws (75).

The use of a combination of long fingers (71) and short fingers (73) on each end of each base member (63) provides a joint between adjacent base members (63) that has a greater strength than if all of the fingers (69) on one end of a base member (63) were the same length.

As with the first example of a pallet system (10), the base members (63) of the second example (60) can also include sockets (77) which are adapted to support the upright members (64) that can be used to help secure a stack of articles on the pallet system (60) and/or to facilitate the stacking of two or more similarly configured pallet systems one on top of another.

Preferably a lower surface (79) of each base member (63) includes a lifting region (81) that is elevated with respect to at least one other region of the remainder of the lower surface (79). The forks of fork lift vehicle can be placed under the lifting regions (81) of a base assembly structure (61) to allow a load of articles (82) supported on the pallet system (60) to be moved about.

FIGS. 14 and 15 show a capping member (83) or cleat which can be used to help secure a load of extrusions on or within the pallet system (60). The capping members (83) can also be designed to assist with holding stacked pallet loads of extrusions secure.

Each capping member (83) includes a socket (85) at each end which is configured to engage with the top end of an upright member (64). The sockets (85) being open at the bottom face of the capping members (83). The capping members (83) span between opposing upright members (64) connected to each side of the base assembly structure (61).

The capping members (83) also include a recessed groove (87) along their length which can be used to retain a packaging strap (89) which can be used to secure the pallet system (60) about a load of extrusions or other elongate products (82).

It can be seen in FIG. 14 that each capping member (83) further includes one or more protrusions (91) at each end, the protrusions (91) extending upwardly from a top face (93) of the capping member (83). Also, a bearing face (95) of each protrusion (91), which faces the opposite end of the capping member (83), is inclined at an acute angle to the top face (93) of the capping member (83). When one assembled pallet system (60) is stacked on top of another, as shown in FIGS. 16 and 17, the lower outside edges of the base assembly structure (61) of the upper pallet system (60) can be held in place by the opposing bearing faces (95) of the capping members (83) of the lower pallet system (60). In this way, a stack of loaded pallets using the pallet system (60) can be kept secure when stacked or when being transported.

The protrusions (91) can also be adapted to engage with the underside of the base assembly structure (61), for example be engaging in corresponding recesses in the base members (63), to prevent longitudinal movement or slippage of the upper pallet relative to the lower pallet.

Variations

Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope thereof.

In the first example of a pallet system (10) described above, the joining members (21) have pins (27) and the base members (13) have complimentary sockets (23). In an alternative embodiment, the pins could be part of the base members (13), and the joining members (21) could include the complimentary sockets.

Also, in the first example described above, adjacent base members (13) are joined using separate joining members (21). However, it is envisaged that in an alternative configuration, the abutting edges of the base members (13) could be provided with complimentary protrusions and recesses that are configured to mate together, for example to form a dovetailed type of joint.

In the second example, the fingers (69) were adapted to be fastened together using one or more fasteners. However, in a further variation, the interlockable elements (67) of each base member (63) could be adapted to snap lock with the corresponding interlockable elements (67) of an adjacent base member (63).

Definitions

Throughout this specification the word “comprise” and variations of that word, such as “comprises” and “comprising”, are not intended to exclude other additives, components, integers or steps.

Advantages

Thus it can be seen that at least the preferred form of the invention provides a pallet system which can be assembled or disassembled relatively easily, and the component parts are not cumbersome and can be transported for re-use with less difficulty than comparable full length pallets. The re-usability provides a pallet system that is less demanding on the earth's natural resources. In at least one variation, the pallet system can be assembled or disassembled without the need for tools.

Kit of Parts

It will also be understood that where a product, method or process as herein described or claimed and that is sold incomplete, as individual components, or as a “kit of Parts”, that such exploitation will also fall within the ambit of the invention. 

1. A pallet system, mountable and demountable without the use of tools, which is adapted to securely transport and/or store elongate or extruded products, the pallet system including a plurality of base members, each base member including interlockable elements on at least one end which are adapted to engage and interlock with a similarly configured adjacent base member such that an elongate base structure can be formed from the base members, and wherein each of the base members is also adapted to support a plurality of upright members, a plurality of upright members adapted to engage and interlock with each of said base members and one or more cap members, the pallet system being further characterised in that it comprises one or more cap members which are adapted to engage with said one or more upright members.
 2. A pallet system as claimed in claim 1 wherein each base member includes the interlockable elements on both ends.
 3. A pallet system as claimed in claimed in claim 1 wherein the interlockable elements include one or more fingers adapted to interlock with corresponding fingers or recesses of an adjacent base member.
 4. A pallet system as claimed in claim 3 wherein the fingers have a substantially “C” shaped cross section.
 5. A pallet system as claimed in claim 1 wherein the interlockable elements are adapted to receive fasteners to further secure any joint between interlocked base members.
 6. A pallet system as claimed in claim 1 wherein the interlockable elements of each base member are adapted to snap lock with the corresponding interlockable elements of an adjacent base member.
 7. A pallet system as claimed in claim 1 wherein each base member is engaged with an adjacent base member using one or more joining members.
 8. A pallet system as claimed in claim 7 wherein each joining member is adapted to engage with one or more first sockets or pins provided on each base member.
 9. A pallet system as claimed in claim 7 wherein each joining member fits into each base member with an interference or a snap fit.
 10. A pallet system as claimed in claim 1 having a joint between each of the base members and wherein the joint between adjacent base members provides a recess or recesses adapted to accommodate or retain a packaging strap.
 11. A pallet system as claimed in claim 1 wherein each base member further includes one or more base sockets, or a part of one or more sockets, adapted to support an upright member.
 12. A pallet system according to claim 11 wherein the one or more cap members has at least one recess or channels sufficient to accommodate or retain packaging strap material.
 13. A pallet system as claimed in claim 1 wherein each base member has a generally rectangular or square shape when viewed from above.
 14. A pallet system as claimed in claim 1 having one or more legs which extend below a body section of each base member adapted to accommodate a lifting means.
 15. A method of palletising elongate or extruded products without the use of tools including the steps of: (i) engaging two or more pallet bases to form a generally elongate single pallet base, each pallet base having a plurality of sockets adapted to accommodate a plurality of upright members and one or more recesses located at or about the join between each pallet base, (ii) engaging a plurality of upright members into the sockets provided in the pallet base (iii) loading the pallet base with elongate or extruded products, (iv) placing one or more cap members over the elongate or extruded products and engaging the cap members with the upright members to enclose the elongate or extruded products, and (v) applying a packaging strap about the loaded pallet at least at each location where a base member is joined to an adjacent base member.
 16. (canceled) 